IR 05000498/1986034

Insp Repts 50-498/86-34 & 50-499/86-34 on 861006-1128.No Violations or Deviations Noted.Major Areas Inspected:Action on Previous Findings,Reported Items,Ie Bulletins & Notices, Reactor Vessel & Internals & safety-related Piping

ML20207L595
Person / Time
Site:	South Texas
Issue date:	01/02/1987
From:	Constable G, Garrison D, Clay Johnson NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20207L578	List: IR 05000498/1986034 ML20207L575
References
50-498-86-34, 50-499-86-34, NUDOCS 8701120250
Download: ML20207L595 (15)

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APPENDIX

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U.S. NUCLEAR REGULATORY COMiISSION

REGION IV

NRC Inspection Report: 50-498/86-34 Construction Permits: CPPR-128 50-499/86-34 CPPR-129 Dockets: 50-498 50-499 Licensee: Houston Lighting & Power Company (HL&P)

'P. O. Box 1700 Houston, Texas 77001 .

Facility Name: South Texas Project, Units 1 and 2 (STP)

Inspection At: STP,-Matagorda County, Texas Inspection Conducted: October 6 through November,28, 1986

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Inspectors: - s

' rE. ilohnson, Senior Resident Inspector

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roject Section C, Reactor Projects Branch

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L. Garrison, Resident Inspector, Project 1/t/9 7 Date

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Section C, Reactor. Projects Branch-7'

Approved: _

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G. t ' Constable,' Chief, Project Section C Da'te '

Reactor Projects Branch Inspection Summary Inspection Conducted October 6 through November 28, 1986 (Report 50-498/86-34; 50-499/86-34)

Areas Inspected: Routine, unannounced inspection, including site tours, licensee action on previous inspection findings, reported items, IE bulletins and notices, reactor vessel and internals, safety-related piping, structural steel, and heating, ventilating, and air conditioning (HVAC) system Results: Within the nine areas inspected, no violations or deviations were identifie PDR ADOCK 05000498 y Q PDR

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DETAILS

. Persons Contacted Principal Licensee Employees

• J. T. Westermeier, Project Manager

• S. M. Dew, Deputy Project Manager

• J. E. Geiger, Manager, Nuclear Assurance

• S. Head, Licensing Engineer

• H. Kinsey, Plant Manager

• McIntyre, Project Engineer

• J. D. Green, Operations Quality Assurance Manager

• T. J. Jordan, Project Quality Assurance Manager

• S. Shukla, Licensing Engineer Bechtel Power Corporation (Bechtel)

• D. L. Long, Unit 1 Manager

• A. Zaccaria, Project Manager

• L. W. Hurst, Project Quality Assurance Manager Ebasco Services Inc. (Ebasco)

• A. M. Cutrona, Quality Project Site Manager

• D. D. White, Site Manager

• Denotes those individuals attending the exit interview conducted on November 26, 198 In addition to the above, the NRC inspectors also held discussions with other members of the HL&P, Bechtel, and Ebasco staff . Site Tour The NRC inspectors made numerous tours in order to observe in process work and the condition of the plant and equipment. The following areas were inspected: isolation valve cubicles (IVC), mechanical, electrical auxiliary building (MEAB), reactor containment building (RCB), fuel handling building (FHB) and associated areas. In Unit 2 after a flooding condition occurred on October 23, 1986, the NRC inspectors specifically toured the MEAB at the 10 foot elevation including the electrical penetration room, auxiliary shut down room, power cable vault and electrical switchgear rooms, component cooling water (CCW) pump rooms, HVAC chillers, and positive and centrifugal charging pump rooms. The flooding occurred because of incomplete construction involving some open penetrations and grading problems around the IV I

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.The following list of major safety-related equipment had been partially submerged in water:

Electrical: Motor Control Centers 15KV Switchgear-Inverters Voltage Regulated Transformers 120 Volt AC Distribution Panels

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Battery Chargers 125V DC Distribution Panels 125V DC Distribution Switchboard Relay Cabinets Isolation Cabinets 480 Volt Load Center 4.16 KV Switchgear Distribution Transformers Mechanical: Centrifugal Charging Pump Auxiliary Pump Boric Acid Transfer Pumps Reactor Makeup Water Pump 22 Pieces of Liquid Waste System Equipment classified as Non-Nuclear Safety (Class 7)

In the FHB the three containment spray, three high head safety injection, and three low head safety injection pumps were under water. These are vertical pump motor sets. The water did not get up to the motor In the IVC, the four auxiliary feed water pumps (motors not installed) and four steam generator recirculation pump / motor combinations were completely submerge The water depth in the three buildings were as follows:

. IVC (12 feet)

. MEAB (18 inches)

. FHB (8 feet)

The licensee is investigating the effects of the flooding in an orderly and methodical manner and in accordance with their nonconformance procedur No violations or deviations were identifie . Licensee Action on Previous Inspection Findings (0 pen) Open Item 498/8623-01 This item concerned a welder identification (ID) identified on the hardware but not documented on the American Welding Society (AWS) welding checklist. This was left as an open item because the licensee had previously identified a similar deficiency which was documented on Site

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Deficiency Report (SDR) No. H-338 Review of the licensee's' response indicated that the method used to determine a 95/95 confidence level was in error. This item is open pending the licensee's correction of the erro (Closed) Violation 499/8621-01 This item concerned the unsatisfactory storage of fabricated pipe suppor sway struts. Since identification of the problem, the licensee has taken immediate corrective action. Reinspections of these items in storage throughout the site indicates that the corrective measures were satisfactor (Closed) Violation 499/8623-02 This violation consisted of three parts; (1) removal of temporary supports without authorization, (2) construction did not check / verify the main steam (MS) line in Unit 1 IVC A and C after hydrostatic testing resulting in the bottoming out of variable spring hangers, and (3) travel stops in variable spring hangers were removed without approval from engineerin The licensee has adequately addressed the problem and corrective steps to prevent recurrence have been initiate (Closed) Unresolved Item 498;499/8316-01 This item concerned audits that were apparently not performed on Bostron-Bergen Metal Products during the 1977-1979 timeframe. This item was a matter of concern during an NRC inspection in 1983. Since this time, the Brown and Root (B&R) transition has been completed and new programs in place have verified the adequacy of the structural steel program and adequate corrective action has taken plac (Closed) Unresolved Item 498;499/8316-02 This item concerned an apparent discrepancy of not including reference standards in some. purchase orders and questioned the tightening of some bolts. The licensee onsite quality control (QC) program was adequate at the time to determine if discrepancies existed. The present program has verified that the structural program meets 10 CFR 50 Appendix B requirements including the inclusion of adequate standards in purchase order (Closed) Unresolved Item 498;499/8316-04 This item concerned invoking Amercian National Standards Institute (ANSI)

standards on vendors of structural steel items. Since the original inspection, the licensee has become more aware of reference standards in purchase order At this time, the license program for purchasing, including requisitioning, is adequately reviewed for inclusion of applicable requirement .. _- . . - ._ . _ _ - - . - - _ .

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(Closed) Unresolved Item 498;499/8316-05 *

The NRC inspector had identified problems with bolting and structural steel connections in the polar crane structure. Also included was a drawing error. The_NRC inspector has reviewed the corrective action taken by the licensee and found it adequat (Closed) Unresolved Item 498;499/8316-06

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This. item pertains to American Society for Testing and Materials (ASTM)

A449 bolts that are used to connect the polar crane rails to each other using a slotted clip. These nuts / bolts have been installed in accordance with drawing 2C26-95-1025 and specifically note No. 2 which requires that tightening be by the turn-of-the-nut method (1/2 turn).

(Closed) Unresolved Item 498;499/8204-01 This item concerned a large number of bolts and nuts which were questionable. Since the identification of this problem, the licensee has instituted procedural controls which have~been verified by the NRC inspector in the course of the NRC inspection program including the corrective action to the Construction Appraisal Team (CAT) inspection (NRC Inspection Report 50-498/85-21; 50-499/85-19).

(Closed) Unresolved Item 498;499/8403-01 This item concerned a possible lack of receiving inspection reports (RIRs)

for safety-related material Phase 2-of the anchor bolt program has verified that RIRs are available for all safety-related material (Closed) Violation 498/8519-01 This item concerned the failure to follow procedures. Filler material issue records (FMIRs) for some supports listed welders who appeared to have performed work on the support but were not identified on the multiple process data checklist (MPDC). The NRC inspector reviewed the licensee's response to the notice of violation (NOV), and considers the response adequat .- Licensee Action on Previously Reported Items (10 CFR 50.55e)

The NRC inspector reviewed the following deficiency evaluation reports (DER) and determined that no further action is necessary.

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(Closed) DER-85-010 (IRC No. 236)

This item concerned a fabrication interference between the forged sway-strut eye-rod and the machined rear bracket (on one end of a sway-strut), and between the forged sway-strut eye-rod and the clamp-bolt spacer (on the other end of a sway-strut).

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The possibility of this interference (whieh is caused by excess forging

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" trim" or " flashing" on the end of the eye-rod) exists on at least the

, : size 6,:10, and 14 struts with the machined brackets,' and/or the size SPC-10-160 and SPC-14-180 clamp The NRC inspectors have determined by review and verification that the licensee's corrective action and recurrence control is adequat (Closed) DER 85-009 (IRC-230)

In report 85-06 a closure item was described as DER-84-011 (IRC-195); this is. incorrect and should be DER 85-009 (IRC-230).

' Licensee Action on IE Bulletins-(IEBs)

The following seven IEBs were reviewed by the NRC inspector and found to contain adequate licensee action and are.therefore considered closed:

IEB - 71-01 MSIV Closure Problem-IEB - 71-03- ' Relief Valves Blown Off Header IEB --72-01 Hanger Failure IEB - 72-02 Actuation of SI Signal IEB - 73-03 Defective Shock Suppressors IEB - 73-04 Defective Shock Suppressors IEB - 74-02 Truckers Strike- Licensee Action on IE Notices (IENs)

Eighteen IENs were reviewed by the NRC Inspectors. It was found that the licensee has responded.to the expressed concerns. The following IENs are considered closed:

IEN - 79-005 Materials Problem IEN - 79-010_ Pipe Support Struts IEN - 79-011 Insulation Supports IEN - 79-013 Low Water Level IEN - 79-012' . Fuel Assembly Damage IEN - 79-012a Fuel Assembly Investigation IEN - 79-015' Procedures IEN - 79-022 Control Systems IEN - 79-028 Overloads of Structural Items IEN - 79-029 Loss of Coolant IEN - 79-036 Defect in Computer Code IEN - 79-031 Incorrect Response Spectra IEN - 80-003 Electro-Hydraulic Control IEN - 80-007 Pump Shaft Cracking IEN - 80-010 Loss of Non-Safety Instrumentation IEN - 80-012 Instrument Failure IEN - 80-013 Control Switch Cam Followers IEN - 80-015 Fracturing in Pipe Welding

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- - Reactor Vessel and Internals - Unit II-L' l Quality Assurince (QA) Review (Procedures)

, The Final Safety Analysis Report (FSAR) in chapter 4.2.4.1 commits to a QA Plan developed by Westinghouse for use as the qualified American Society for Mechanical Engineers (ASME) manua This progra provides for control of all activities and is written in the format of.10 CFR 50 Appendix The Westinghouse QA Program Manual was examined for conformance to 10 CFR 50 Appendix B, and'ASME Section III requirements for record The manual was found to be complete and adequate to cover the work performed. The manual contained adequate forms for documem.ing i

ultrasonic, radiographic, liquid penetrant, visual and traveler work cards, and other forms for recording the work effort.

! Bechtel specification 3R101NS1003, Revision 4, is a generic (

specification from which Ebasco can develop procedures which will interface with Westinghouse. The specification was general in nature.

i and adequate for its-intended purpos Westinghouse process specification 597760, Revision 5, " Cleanliness

- and Housekeeping," was reviewed and found to be satisfactory for .'

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their work and equipment from initial installation of the vessel to -

insertion of the internals. Westinghouse equipmentzis generally =

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specification 5A300GS1002, Revision 8, was found to be adequate fo the material and equipment when under contractor storage contro '

) - Westinghouse specification 80281RG, Revision'2, " Reactor Internals

Field Fabrication Requirements," was reviewed and found to include

!. the basic requirements for fabrication and welding to different l sections of the ASME code.

.; Westinghouse specification 80280LM, Revision 7, " Reactor Internals *

. Fabrication Requirements," generally details the same requirements as j specification 80281RG including cutting, welding, filler materials,

sensitization, heat treatment, and cleaning.

h The'following three procedures interface or have control of

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effort. These were found to be adequate for their intended purpose.

4 . Standard Site Procedure (SSP) 52, " Installation, Assembly and j

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Disassembly of Permanent Plant Mechanical Equipment"

. Construction Site Procedure (CSP) 29, " Reactor Vessel Internals Handling and Assembly"

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. Quality Control Procedure (QCP) 12, " Maintenance

' Inspection / Verification" It_was concluded by the NRC inspector.that there are ample

_ specifications ~and procedures to cover all aspects of handling and'

fabricating the vessel internals and sufficient' documents to record the event Work Observation The NRC inspector made several observations of the internals lifting-stand and the. internals lifting device for welding and bolting quality, and any apparent damage. No problems were noted on these

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two items. The reactor head and assembled control rod drives were-adequately protected with plastic-covers. The reactor vessel is set with a steel cover on-its top. The only ongoing work was that the craft.were cleaning and applying Lubriplate No. 1 to the threads and bearing surface of the 3/4 inch X 2.63 inches socket head cap screws

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used to secure the' bottom mounted instrument columns to the lower plate. This work was being performed in accordance with work package traveler T-THX-210, " Assembly of the Lower. Internals."

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Documents used to conduct the inspection are list below:

W Drawing 1216E71, Revision 1 W Drawing 1217E10, Sheets 1 - 5-W Drawing 1216E90, Revision 1, sheets 1 and 2 W Drawing .

1217E90, Sheets 1-W Work Package T-THX-210 The 3/4 inch X 2.63 inches socket head cap screws were identified as Code R501 which was marked as Heat G1641. Westinghouse provided a copy of the mill test report for review and it was determined that the parts were of the correct material and were processed per the

' Westinghouse specificatio Records The NRC inspector reviewed traveler T-THX-210, which.is the assembly instruction for the entire lower internals. -There were no discrepancies identifie . Piping (Safety-Related) Unit II

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The purpose of this inspection was to review the licensee program for manufacture, storage, work quality, design and records in the area of fabricated spool pieces. Included in the inspection were seven spools of safety-related and three spools of auxiliary systems pipe. The NRC inspector assessed the design commitments, workmanship and associated

records.

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9 Procedures Review The NRC inspector reviewed section 3 of the FSAR which outlines the plant equipment and separates the systems and components into various safety classification Table 3.2 A-1 outlines the plant components according to class (safety, standard or code, seismic category, and QA). Table 3.2.B1 applies the same classifications to the Westinghouse fluid component The classifications are further detailed in Bechtel specification SL019PS004, Revision 11, " Criteria for Piping Design,"

which includes a complete service inde Specifications 5A010PS002, Revision 10, " Piping Erection and Field Fabrication," and 4LO20PS0100, Revision 6, " Fabrication of ASME Section III Piping 2 1/2 inches and Larger," outlines the requirements to be used by construction and QC for shop fabrication and field erectio SSP 17 and 18 (Welding) outline the requirements for pipe welding and SSP 10, " Installation and Field Fabrication of Piping," sets forth the requirements of installation detail These procedures contain the design requirements necessary to implement the piping program thru QC inspection and acceptance. The procedures also include the necessary instructions to assure quality workmanship, documentation and authorized nuclear inspector (ANI) revie Several other procedures are available in the SSP manual to assure that all phases of the QC program are carried out in accordance with the licensee commitments and regulatory criteri No items of noncompliance were observed in the review of the proceeding document b. Control of Fabricated Pipe Ten fabricated pipe spool pieces in yards A, B, and C were randomly selected from the card files in the yard offic These pieces were located at the correct locations called for on the locator card The spool pieces were fabricated by Dravo or Southwest Fabricating Compan The pieces were checked for conformance to the constructica or fabricator drawings and the Bechtel isometric drawings. Also each assembly was inspected for weld quality, configuration, storage markings, and overall workmanship. The storage yards were noted to be well laid out with adequate drainage and all of the piping was resting on dunnage. The spool pieces inspected were:

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System Identification Location Liquid Waste WL-2135-D MA-238 Safety Injection SI-2103-B MB-210 Steam Generator Blowdown SB-2305-B MA-241 Residual Heat RH-2115-K MA-137 Reactor Coolant RC-2046-C MA-411 Main Steam MS-2130-A- MB-411 Heater Drain HD-2136-C1 MA-326 Feedwater FW-2009-A MA-331 Condensate CD-2076-C MA-416 Condensate Polisher CP-2484-D MC-207 The corresponding design isometrics reviewed were:

7M369PWL277, sheet A35 7G362PMS2130 2F362 PSI 2103 8G369PHD836, sheet 14 SG369PSB688, sheet 7 7G369PFW833, sheet 1 4C369PRH459, sheet 4 8G369PCD808, sheet 14 4C369PRC457, sheet 4 9Y369PCP713, sheet 10 No discrepancies.were noted concerning the pipe spool pieces in the storage yard Records Review The records packages for the preceding spool pieces were retrieved from the document control vault using the computer assisted retrieval system:

WL-2135-WG7-D MS-2130-MC7-A SI-2103-KB2-B HD-2136-SG8-C1 SB-2305-SH7-B FW-2009-EC7-A RH-2115-KB2-K CD-2076-XC8-C RC-2046-BB1-C CP-2484-WX9-D Each package was reviewed to the standard for its particular safety classification. The packages were complete or cross referenced other data to complete the package such as the purchase order, material receiving reports, requisition No discrepancies were noted in the retrieval of drawings from the field document control center (FDCC) or records from licensee vaul . Structural Steel Observation The NRC inspector visually examined partially completed in process structural supports and miscellaneous details in Unit 2 RCB to

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determine.if these, supports and details were in compliance with I' current design / installation drawings and any field change request-(FCR) modifications.

i ~ The NRC inspector selected carbon unit fans. supports-A and B,:and two

, reactor containment fan cooler (RCFC) fan supports FN004 and FN006 r 'for inspectio The NRC inspector verified that the following, items were implemented in the installation / erection process:

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. The structure / support was being erected in accordance with the

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current procedures and vendor drawing Fit-up/ alignment met Se tolerances in. specifications.and~

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drawing . Specified clearances were being maintaine . Welders were qualified.

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. _FCR's and any modifications were included in fina11 acceptanc . For bolted connections: -bolts, nuts, and washers were of the specified type and grad .

. For welded connections: welds were of.the required size and had no visual rejectable defect The NRC inspector also conducted random interviews with field

, engineers and QA/QC inspectors to ascertain their knowledge of the work activity being performed. All persons interviewed were knowledgeablelof their discipline. All three structural supports

were in proces .

Drawings used to examine supports are listed below:

Bechtel AFC0 3C01-9S-1508, Revision 5 14926-6306-04673-BVM

'3C01-95-1603, Revision 4 14926-6306-04697-AVM 3C01-9S-1501, Revision 10 14926-6306-01421-AVM 3C01-9S-1502, Revision 10 14926-6306-01428-AVM t 3C01-95-1507, Revision 4 14926-6306-01429-AVM 3C01-9S-1508, Revision 5 14926-6306-01430-BVM

! 3C01-95-31022, Revision 0 14926-6306-01431-AVM

SV14-9V-0090, Revision 3 14926-6306-04674-AVM 8V14-9V-0097, Revision 4 14926-6306-04694-AVM

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American Bridge 14926-8019-01274-AAB No violations or deviations were identified.

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b. Records The NRC inspector reviewed records of the HVAC support structures examined previously to determine if records reflect work accomplishments consistent with specifications and procedure Installation records reviewed confirmed that the required inspections, including welding, bolting, and torquing were performed, and acceptance criteria was define The NRC inspector also reviewed FCR's associated with the HVAC support structures and details, to determine if they had been incorporated and reflected the as-built condition. The NRC inspector also selectively examined QC marked up drawings to determine if the inspection reports generated for the activity were properly documented as required by procedure on the drawing indicating the correct connection or detail inspecte It appears that the licensee's system for preparing, reviewing, and maintaining records is functioning properl Records review are listed below:

Welding IR's Bolting IR's 2-05019 QE2-0208 2-05027 QE2-0209 2-04967 QE2-0213 2-05018 01128E 1-00813 01251B 1-00609 305482 1-00536 QE2-0126 1-00535 QE2-0168 1-00534 3099B1 1-00524 3100B1 1-00454 3095B1 1-00453 3094B1 3052-B1 02041B Construction Traveler N V142VFN004 2V142VFN006 2V142VFN005

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2V142VFN003 2V142VFN002 2V142VFN00 . Audit Reports 1

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The NRC inspector reviewed audit reports C14-502,. dated July-8,'1985,.

and-C14-601, February 11,.1986. HL&P project'QA performed both

- audits of Ebasco. structural steel installation activities at.the ST The purpose of the audits was to verify the programmatic adequacy and proper procedural implementation of quality-related activities

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dealing with fabrication _and installation of structural stee The

' audit team was composed of HL&P, Bechtel and Ebasco QA personne Records established that the required audits were performe Records also indicate that deficiencies identified during audits were addressed,' and that corrective action was initiate No violations or deviations were identifie . Safety-Related'HVAC System Observation

--The NRC inspector examined portions of'the last Unit 1 HVAC system completed which were subsystem, HZ-11, in 'the IV The NRC inspector visually examined the duct, duct supports and

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accessories in IVC Bay 2, and the orientation and configuration i ,

IVC Bay 3 from elevation 27 feet to 68 feet. It was determined by the NRC inspector through-direct observation and independent evaluation of work, that.the~' installation of safety-related HVAC systems in the IVC was'in compliance with licensee commitments, and code No violations or deviations were identifie b, Records The NRC inspector reviewed the records associated with the ducts, duct support and accessories that were examined above. The records indicate that the licensee appears to be adequately preparing, reviewing, and maintaining a system of quality records. There is reasonable assurance that the records reflect the work-accomplished and are consistent with NRC requirements and FSAR commitment The documents reviewed during this inspection are as follows:

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Reference Drawing No. 5-V-14-1-V-0132-CID, Revision 1 i

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Supports:

1-8-0132-S010-(0133), Revision 0 and 1 1-8-0132-S011 (0133)

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1-8-0132-C-0034, Revision 0 and 1 Ducts:

1-8-0132-304 1-8-0132-303

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1-8-0132-215, Revision 0 and 1 Reference Drawing No. 5-V-14-1-V-0132-BID, Revision 1 Supports:

1-8-0132-S057 (0141)

1-8-0132-S059 (0141)

1-8-0132-S061 (0141)

1-8-0132-5063 (0141)

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1-8-0132-5065 (0141)

Accessories:

1-8-0132-SAR-C-03 1-8-0132-SAR-C-07 1-8-0132-C-018 Ducts:

! 1-8-0132-203

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1-8-0132-204 l 1-8-0132-205 i 1-8-0132-206 i 1-8-0132-207 1-8-0132-208

! 1-8-0132-209

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1-8-0132-210 1-8-0132-211

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1-8-0132-212 1-8-0132-213

1-8-0132-214, Revision 0 and 1 l No violations or deviations were identified.

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11. Exit Interview-l

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The NRC inspector met with licensee representatives (denoted in- .

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paragraph 1) on November 26, 1986, and summarized the scope and finding of the inspection.

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